RITE-HITE DUAL-DOK 2200 Owner'S Manual Download Page 78

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Pub. No. 1290 - January 2010

RITE-HITE

Dual-Dok

Combined Lift & Leveler System Owner’s Manual

REPLACEMENT PARTS - MANIFOLD

8
9

202

204

203

205

SV1

LRV

201

SRV

200

Top View

Bottom View

Item Qty.

Description

Part Number

Fixed P.C. F.C.

55192

Check – 100 PSI

55193

24 VAC H.C. Coil

55360

Valve, 2-way, N.O. Spool (203, 204)

55189

Check – 5 PSI

55234

Valve, 2-way, N.C. Poppet (202)

55185

Check – 75 PSI

68151

Valve, 4-way, 2-Position Spool (205)

55184

Valve, 3-way, 2-Position Spool (200, 201)

55186

Scissor Relief Valve (3000 PSI)

68152

Leveler Relief Valve (1000 PSI)

68153

12 1 Sequence

Valve

68154

Ball Check – 5 PSI

55190

Summary of Contents for DUAL-DOK 2200

Page 1: ...ruck trailer until its brakes are set air has been dumped from air ride suspension if applicable and you have visually inspected to be sure truck trailer is securely held in place by a vehicle restrai...

Page 2: ...2 Pub No 1290 January 2010 RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual NOTES...

Page 3: ...557 5 546 623 5 553 987 5 582 498 5 664 930 5 702 223 5 762 459 RE 37 570 5 882 167 5 964 572 6 010 297 6 052 268 6 065 172 6 070 283 6 074 157 6 085 375 6 092 970 6 106 212 6 116 839 6 190 109 6 220...

Page 4: ...he tag to deteriorate or become unreadable RITE HITE Corporation does not recommend any particular lockout device but recommends the utilization of an OSHA approved device refer to OSHA regulation 191...

Page 5: ...wn under Safety Warnings on preceding page TO ENGAGE SUPPORT LATCH 1 Bring platform to dock floor height 2 Pull activation chain in an upward motion to lower support latch 3 While holding the activati...

Page 6: ...nd that one person attempt to lift the lip alone To engage the lip support press the MANUAL RESET button along with the LIP OUT button to extend the lip Pull out the lip support bar as shown below Tur...

Page 7: ...20 The LED will change from GREEN position to the RED No controls will functions until the outside light has been changed to RED Remove wheel chocks and or restraint only when loading or unloading is...

Page 8: ...l weight on the platform empty forklift stack of pallets can cause the system to display a fault condition The rear pivot pins will engage automatically if the DUAL DOK system is not operated for 5 mi...

Page 9: ...es should be kept 5 As with any piece of machinery dock equipment requires routine maintenance lubrication and adjustments Your local RITE HITE representative offers owners the option of a Planned Mai...

Page 10: ...elow dock for 15 minutes MANUAL FUNCTIONS Leveler Raise Disengage Pins Lip Extend Extend Lip Auto Lip Unlock Velocity Fuse Lift Up Raise Lift Lift Down Lower Lift Press MANUAL RESET button to reset DU...

Page 11: ...ed Lift Leveler System Owner s Manual INSTALLATION INSTRUCTIONS CONTINUED Before starting installation or maintenance check and follow the safety procedures of the facility where the DUAL DOK is being...

Page 12: ...ING CHAIN ROUTE SUGGESTED LIFTING CHAIN ROUTE HOOK BACK OVER CHAIN LIFTING UNIT 4 PLACES BE SECURE WHEN SHIPPING BANDS MUST INSTALLATION MUST BE BEHIND ROUTING OF WIRE BUNDLES DURING CHAIN WHEN LIFTIN...

Page 13: ...t Down Lower Lift Press MANUAL RESET button to reset DUAL DOK after a fault has been cleared at dock height If a fault has been cleared below dock height press MANUAL REST button and corresponding man...

Page 14: ...e with anyone standing under or in front of leveler 3 Never enter a truck trailer until its brakes are set air has been dumped from air ride suspension if applicable and you have visually inspected to...

Page 15: ...SE FRAME ASSEMBLY FLOOR MOUNTING PLATES FOR CLARITY DIAGRAM ONLY SHOWS BASE FRAME AND PIT FRONT OF PIT BACK OF PIT SIDE OF PIT 4 ROLLER BAR REAR PIN PLATES NOTE IF SHIMMING IS REQUIRED POSITION SHIMS...

Page 16: ...NSTALLATION INSTRUCTIONS CONTINUED DETAIL REAR SEAL CHANNEL 6 5 7 WIDE UNITS 7 5 WIDE UNITS 53074 53075 56518 56519 BRUSH SEAL CHANNEL SECTION A A A A 25 TYP 53073 2 REF 53074 2 REF NOTE 1 EACH PER SI...

Page 17: ...the following safety devices a Push in the selector valve b Turn on power c Disengage the support latch by returning the platform to dock height by pressing and holding the Lift UP and MANUAL RESET b...

Page 18: ...8 With the DUAL DOK system in the Lift Mode lower the unit about 12 and then return to dock height RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual INSTALLATION INSTRUCTIONS CONTINUED Th...

Page 19: ...TE HITE Dual Dok Combined Lift Leveler System Owner s Manual INSTALLATION INSTRUCTIONS CONTINUED IMPORTANT Position Pivot Block With Chamfer Facing Rear Hinge Pin 6 Ref 1 4 Ref 1 4 1 4 1 4 Tack 2 Side...

Page 20: ...rresponding manual function button to move unit to dock height ADDITIONAL WARNINGS AND INSTRUCTIONS ON SIDE OF ENCLOSURE 1 Do not operate leveler with anyone standing on or in front of leveler 2 Do no...

Page 21: ...ut Solenoid Pin Disengage Solenoid Limit Switch Power Pins Disengaged Limit Switch Pins Engaged Limit Switch At Dock Height Limit Switch Below Dock Height Limit Switch Platform Separation Limit Switch...

Page 22: ...ort latch by pulling the activation chain and pressing and holding the Lift DOWN button until the platform stops decending as shown in Figure 2 Pulling the selector valve activation chain out to preve...

Page 23: ...IGHT WARNING WARNING Lip Platform LEVELER LIFT MILWAUKEE WISCONSIN 1 800 456 0600 COMBINED LIFT LEVELER SYSYEM 0126280 REV XX R R F1 F2 F3 F4 FIGURE 20 STORED POSITION Control Box Outside Lights Red G...

Page 24: ...ight ADDITIONAL WARNINGS AND INSTRUCTIONS ON SIDE OF ENCLOSURE 1 Do not operate leveler with anyone standing on or in front of leveler 2 Do not operate in any mode with anyone standing under or in fro...

Page 25: ...or in front of leveler 3 Never enter a truck trailer until its brakes are set air has been dumped from air ride suspension if applicable and you have visually inspected to be sure truck trailer is se...

Page 26: ...er 3 Never enter a truck trailer until its brakes are set air has been dumped from air ride suspension if applicable and you have visually inspected to be sure truck trailer is securely held in place...

Page 27: ...visually inspected to be sure truck trailer is securely held in place by a vehicle restraint or wheel chock per OSHA regulations Outside light is on when LED flashes Check outside lights is both LEDs...

Page 28: ...e suspension if applicable and you have visually inspected to be sure truck trailer is securely held in place by a vehicle restraint or wheel chock per OSHA regulations Outside light is on when LED fl...

Page 29: ...draulic velocity fuses These fuses act as check valves to stop fluid flow if the flow exceeds the valve s rating Both lift and ramp cylinders have an in line velocity fuse at the base of the cylinder...

Page 30: ...ing the Lift DOWN button until the platform stops decending as shown in Figure 2 Pulling the selector valve activation chain out to prevent scissors movement as shown in Figure 4 If lip needs to be ex...

Page 31: ...ins with anti seize lubricant See Figure 28 5 Spray lubricate on all pins and cylinder rods See Figure 28 6 Check hydraulic reservoir for proper fluid level 7 Check all hydraulic cylinders hoses and f...

Page 32: ...the safety devices as described in the following Danger 8 Check for fluid leaks and verify that the hydraulic fluid level is correct with the unit resting at dock height in the stored position See Fig...

Page 33: ...orm is not at dock height Function Key Descriptions Main PLC Inputs Displays the status of control box PLC inputs Main PLC Outputs Displays the status of control box PLC outputs Faults Displays the la...

Page 34: ...1 COM 2 IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 IN 9 IN 10 COM 1 COM 1 COM 1 COM 2 COM 2 NORMALLY CLOSED HELD OPEN NORMALLY OPEN HELD CLOSED NORMALLY CLOSED HELD OPEN NORMALLY OPEN HELD CLOSED NORMAL...

Page 35: ...202 0208 0209 0200 0201 0202 0203 0204 0205 0206 0207 0205 0204 0203 0202 0201 0200 PLATFORM BELOW DOCK LEVEL PLATFORM BELOW DOCK LEVEL PLC I O INDICATOR LIGHT ON PLC I O INDICATOR LIGHT ON OR OFF L S...

Page 36: ...RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual FAULT CODES Never be under the DUAL DOK platform or lip without Engaging the support latch by pulling the activation chain and pressing...

Page 37: ...long too long Oil is low in tank Check the oil level in tank Hydraulic hose is broken or valve Replace any broken or worn is leaking hoses or valves Filter or return line is plugged Replace filter Rem...

Page 38: ...unning to long or Verify all limit switch wire time out loose connections with 24VDC connections voltages and PLC input terminals continuities Gate limit switches or cables Verify that the gate limit...

Page 39: ...Replace pin limit switch assembly Power was interrupted when motor Disengage pins by pressing the was running while lifting up unit Leveler RAISE button along with the MANUAL RESET button Then raise u...

Page 40: ...hat the lip limit switch and or limit switch actuator is assembly is not damaged or improperly set set incorrectly Pressure on lip sequence valve Increase the pressure on lip SV1 is set too low sequen...

Page 41: ...L OPERATION extended into pivot blocks RESET button along with Lift UP button until platform is at dock height or stops automatically Leveler Mode Platform Locked or not lowering onto 1 Press and hold...

Page 42: ...isengaged 2 Press and hold MANUAL OPERATION RESET button along with Lift DOWN button until platform is at dock height 3 If platform went below dock height press and hold MANUAL OPERATION RESET button...

Page 43: ...etc c Check oil filter for excessive contamination d Remove and examine return line for debris e Check collar and key connecting pump to motor f Check hoses valves and fittings for leaks or damage g...

Page 44: ...ht selector switch is f Verify that outside light selector switch turned to outside GREEN is turned to outside RED Verify that outside light selector switch E6206 is wired and operating properly g No...

Page 45: ...witch is used verify that limit switch wires are connected to terminals 24VDC and E6500 e No power to PLC e Check 110 VAC secondary fuse 10FU1 on lower terminal block assembly Check power across 24 VD...

Page 46: ...while the pins are disengaged and the motor is running Motor overload is tripped Reset overload or replace if necessary Measure amp draw on one power lead and compare to Full Load Amp rating FLA on mo...

Page 47: ...ion keys of the message center Compare limit switch states to State Chart Check or replace A0202 valve coil and wiring terminated at junction box g Hydraulic system g Check and or repalce A0200 3 way...

Page 48: ...ght May be held closed e Hydraulic system e Check and or repalce A0200 and A0201 3 way 2 position spool valve and or A0202 normally closed pilot operated poppet valve May be stuck Increase the pressur...

Page 49: ...nd terminals 24 VDC 24 COM of PLC for 24 VDC c Electrical system c Check outside light selector switch E6206 for loose wires or damaged components Check voltage to outside light bulbs for 24 VAC Check...

Page 50: ...t switch states to State Chart Check push buttons and pendant station for loose wires or damaged components 17 Unit will not complete a Electrical System a Check all limit switch inputs using the weig...

Page 51: ...Pub No 1290 January 2010 51 RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual HYDRAULIC SCHEMATIC FIGURE 32 HYDRAULIC SCHEMATIC FOR STANDARD CAPACITY DUAL DOK SYSTEM...

Page 52: ...NOTES FUSED DISCONNECT IS OPTIONAL FROM RITE HITE PRODUCTS CORPORATION FUSED DISCONNECT MUST BE INSTALLED PER LATEST EDITION OF UL508A AND NEC REQUIREMENTS A BRANCH CIRCUIT DISCONNECT SHALL BE LOCATED...

Page 53: ...ELM TD 13FU1 DUAL ELM TD 2 10A 250V 24VDC BL 24 VDC 24 COM 1762 L40BWA PLC DISPLAY GND 24VDC BL 24 BL 24 BL 24 BL COMM PORT COMM PORT COMM CABLE 212 222 219 221 220 218 217 216 215 214 213 211 210 209...

Page 54: ...GHT SELECTOR SWITCH BUTTON LIFT DOWN BUTTON LIFT UP BUTTON AUTO LIP BUTTON LIP OUT BUTTON BUTTON MANUAL RESET RAISE LEVELER 1762 L40BWA PLC SS1 OX E6204 RD E6205 WH 24VDC BK FACTORY INSTALLED OVERHEAD...

Page 55: ...IN 11 PIN POSITION LS1 SWITCH FLOAT PLATFORM LEVEL RETRACTED LIP EXTENDED LIP SCISSORS SEPARATED SEPARATION PLATFORM BELOW DOCK AT DOCK HEIGHT ENGAGED PINS DISENGAGED PINS TO LINE 501 FROM LINE 324 4...

Page 56: ...2 WH X2 WH 1OL 96 24VAC 70VA A2 SURGE SUPPR 1MCR A1 95 JMPR X2 X2 WH X2 WH X2 WH BEACON HORN NOT ALARM OUTSIDE CAUTION RED LIGHT OUTSIDE GREEN LIGHT INTERLOCK OUTPUT LEVELER STORED STARTER MOTOR DRY C...

Page 57: ...RD A0203 A0203 RD SOLENOID 2 PLATFORM LIP SOLENOID 3 LIFT DOWN A0202 A0202 RD A0201 RD A0201 SOLENOID 1 LIFT UP A0200 X2 WH LIFT UP X2 LIP OUT SOLENOID X2 X2 WH AUTO LIP SOLENOID PLATFORM LIP SOLENOID...

Page 58: ...5 H P 1725 R P M 380v 3 PH 50 Hz FLA 11 0A LEVELER MOTOR 7 5 H P 1725 R P M 480v 3 PH 60 Hz FLA 10 0A LEVELER MOTOR 7 5 H P 1725 R P M 575v 3 PH 60 Hz FLA 8 0A H1 H4 H3 H2 H1 H4 H3 H2 H1 H3 H2 H4 H1...

Page 59: ...10 IN 14 IN 13 IN 12 IN 11 PLATFORM LEVEL LS6 LIP RETRACTED LS5 LIP EXTENDED LS5 SCISSORS SEPARATED LS4 PLATFORM SEPARATION LS3 IN 15 IN 19 IN 18 IN 17 IN 16 NOT USED NOT USED NOT USED FLOAT SWITCH LS...

Page 60: ...Position Desc EO200 201 Pin Limit Switch Desc EO206 207 Lip Limit Switch Desc EO204 Platform Separation Limit Switch Arm Location At Center Of Switch Neutral Position Arm Location At Center Of Switch...

Page 61: ...Pub No 1290 January 2010 61 RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual NOTES...

Page 62: ...System Owner s Manual REPLACEMENT PARTS PLATFORM 57 58 And 59 8 Foot Only 59 2 1 3 4 7 8 9 14 13 12 11 16 15 18 17 36 33 39 35 38 41 52 56 28 29 30 31 32 28 33 40 43 44 41 42 45 13 12 47 46 56 50 49...

Page 63: ...074 24 4 Brush Seal 85 1 2 Long 56518 56518 56518 25 2 Flat Washer 3 4 SAE 51715 51715 51715 26 1 Maintenance Latch 05310 05298 05298 27 1 Extension Spring 1 7 8 O D x 10 3 4 Long 52129 52129 28 2 Ret...

Page 64: ...9 18 17 16 15 13 12 9 10 38 10 39 10 10 40 38 40 41 10 44 43 42 48 49 47 15 45 50 40 40 21 20 24 23 22 8 7 6 5 4 3 Includes Items 4 5 6 And 7 54 59 58 62 56 65 10 14 37 34 33 67 35 36 32 31 29 Include...

Page 65: ...181 06181 19 2 Bushing 2 O D x 1 3 4 I D 52330 52330 52330 20 4 Hex Hd Screw 1 2 13 UNC x 1 1 2 Long 58061 58061 58061 21 4 Lockwasher 1 2 51831 51831 51831 22 2 Cylinder Pin Retainer Plate 59699 5969...

Page 66: ...9 18 17 16 15 13 12 9 10 38 10 39 10 10 40 38 40 41 10 44 43 42 48 49 47 15 45 50 40 40 21 20 24 23 22 8 7 6 5 4 3 Includes Items 4 5 6 And 7 54 59 58 62 56 65 10 14 37 34 33 67 35 36 32 31 29 Include...

Page 67: ...20 UNC 51552 51552 51552 56 1 Guide Rod 59385 59385 59385 57 2 Cotter Pin 1 8 x 1 Long 51901 51901 51901 58 1 Limit Switch Mounting Plate 15763 15763 15763 59 4 Lockwasher 3 8 51833 51833 51833 60 4 N...

Page 68: ...56549 3 1 Base Frame 05308 05336 05202 4 4 Cotter Pion 1 long 51901 51901 51901 5 4 Washer flat 7 16 I D x 13 16 O D 51700 51700 51700 6 1 RITE HITE Logo Decal 54100 54100 54100 7 1 Bellows Curtain F...

Page 69: ...ference 06181 3 1 Lip Cylinder Reference 01380 4 1 Rear Pin Cylinder Reference 06182 5 1 Selector Valve Assembly 06283 6 4 90 Male Elbow 3 8 NPT 8 MJ 55153 7 1 Hose Assembly 06291 8 1 90 Male Elbow 3...

Page 70: ...ence 06181 3 1 Lip Cylinder Reference 06694 4 1 Rear Pin Cylinder Reference 06182 5 1 Selector Valve Assembly 06283 6 4 90 Male Elbow 3 8 NPT 8 MAORB 55153 7 1 Velocity Fuse 7 5 GPM 06195 8 1 90 Male...

Page 71: ...06181 3 1 Lip Cylinder Reference 01380 4 1 Rear Pin Cylinder Reference 06182 5 1 Selector Valve Assembly 06283 6 4 90 Male Elbow 3 8 NPT 8 MJ 55153 7 1 Velocity Fuse 7 5 GPM 06195 8 1 90 Male Elbow 3...

Page 72: ...outside light switch must be turned to RED to operate the system Do not turn switch to GREEN unitl loading unloading is complete Verify that the platform is at dock height and that no load is on platf...

Page 73: ...9 1 Chase Nipple 1 2 55818 20 1 Cord Grip 55714 21 1 Locknut 1 2 55715 22 1 Pendent Station with Cord 16971 23 1 Horn 65750 24 1 Fuse Specification Decal Consult Factory 25 1 Voltage Phase FLA Decal C...

Page 74: ...outside light switch must be turned to RED to operate the system Do not turn switch to GREEN unitl loading unloading is complete Verify that the platform is at dock height and that no load is on platf...

Page 75: ...75V 65689 54 2 Terminal Block Covers with Hardware 65650 55 1 Primary Fuse Block 57605 56 1 Primary Fuse Block Cover 65651 57 2 3A Class CC Fuse 240V 65676 2 2A Class CC Fuse 380V 65677 2 1 4A Class C...

Page 76: ...19 45 44 43 2 5 1 6 7 11 28 Top 15 Bottom 23 Top 22 Bottom 25 Top 24 Bottom 26 Top 27 Bottom 9 10 16 Top 17 Bottom 18 Top 19 Bottom 20 Top 21 Bottom 37 15 GND 24VDC E0200 E0201 E0202 E0203 EO204 EO20...

Page 77: ...204 16467 21 1 Receptacle Plug and Harness Assembly A0203 16468 22 1 Float Switch and Harness Assembly 16471 23 1 Limit Switch and Harness Assembly Plat Lev 16554 24 1 Limit Switch and Harness Assembl...

Page 78: ...Part Number 1 1 Fixed P C F C 55192 2 2 Check 100 PSI 55193 3 6 24 VAC H C Coil 55360 4 2 Valve 2 way N O Spool 203 204 55189 5 2 Check 5 PSI 55234 6 1 Valve 2 way N C Poppet 202 55185 7 1 Check 75 PS...

Page 79: ...51831 51831 51831 6 12 Flat Washer 1 2 STD 51738 51738 51738 7 24 Hex Hd Screw 1 2 13 UNC x 1 1 2 Long 51674 51674 51674 8 4 Guardrite Rail 9600 68 9600 92 9600 116 9 4 Column Newel Cap 55651 55651 5...

Page 80: ...gnal Light Box Complete 6 2 2 4 5 12 25 6 25 3 4 Item Qty Description Part Number 1 1 Outside Light Box With Lamp Assemblies and Lens 18761 2 2 Round Head Screw 8 32 x 3 8 Long 18364 3 2 Light Bulb GE...

Page 81: ...Pub No 1290 January 2010 81 RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual NOTES...

Page 82: ...82 Pub No 1290 January 2010 RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual NOTES...

Page 83: ...Pub No 1290 January 2010 83 RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual NOTES...

Page 84: ...ities and or specified design parameters and not oth erwise abused Periodic lubrication and adjustment is the sole responsibility of the owner This warranty is RITE HITE s exclusive warranty RITE HITE...

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